Multiaxis rotational molding method and apparatus

ABSTRACT

A method of continuously forming integrally molded structures includes the steps of rotating a plurality of independently movable multisection mold assemblies about a plurality of axes, successively flowing a plurality of polymerizable mixtures over surfaces of each enclosed mold cavity while selectively heating mold sections thereof in a preselected heating profile and monitoring the flowing of each mixture, the heating of the mold sections and the formation of resins therefrom. The monitored mixture flowing, the mold section heating and the formation of each resin are coordinated with each monitored axis rotation. The molded structure is removed after it has achieved structural integrity within the mold cavity, and the steps are repeated to form a multiplicity of the integrally molded structures on a continuing basis. Also, multiaxis molding apparatus for conducting the above method.

This application is a continuation-in-part of application No.PCT/US96/15498, filed Sep. 26, 1996, now U.S. Pat. No. 6,296,792 whichin turn is a continuation-in-part of pending application No.PCT/US95/14194, filed Nov. 3, 1995, which in turn is acontinuation-in-part of pending application No. PCT/US95/06301, filedMay 18, 1995, which in turn is a continuation-in-part of applicationSer. No. 08/345,564, filed Nov. 25, 1994, now U.S. Pat. No. 5,503,780,which in turn is a continuation-in-part of application Ser. No.08/249,744, filed May 26, 1994, now U.S. Pat. No. 5,507,632, which inturn is a continuation-in-part of application Ser. No. 08/950,135, filedSep. 24, 1992, now U.S. Pat. No. 5,316,701, which in turn is a divisionof application Ser. No. 07/707,656, filed, May 30, 1991, now U.S. Pat.No. 5,188,845, which in turn is a continuation-in-part of applicationSer. No. 07/417,502, filed Oct. 5, 1989, now U.S. Pat. No. 5,022,838,which in turn is a continuation-in-part of application Ser. No.07/271,686, filed Nov. 16, 1988, now U.S. Pat. No. 4,956,133, which inturn is a continuation-in-part of application Ser. No. 07/202,267, filedJun. 6, 1988, now U.S. Pat. No. 4,956,135, which in turn is acontinuation-in-part of application Ser. No. 06/890,742, filed Jul. 30,1986, now U.S. Pat. No. 4,749,533, which in turn is a division ofapplication Ser. No. 06/766,498, filed Aug. 19, 1985, now U.S. Pat. No.4,671,753.

This invention relates to a novel molding method and apparatus and moreparticularly relates to a new multiaxis rotational molding method andapparatus.

The production of man-made plastic and resin articles is an industrythat utilizes a high degree of automatically controlled continuousprocessing. However, for units of appreciable size, batch processingstill is the rule rather than the exception. For example, in theproduction of fiberglass structures such as boats, it is customary toconstruct the hulls by hand. A plurality of resin and fiberglass layersare sequentially laminated on an open mold or a plurality of mixedresin/chopped fiber coatings are applied over the mold.

Such hand building procedures require a great amount of labor,supervision and continuous inspection to insure that a reasonable levelof quality is achieved. This greatly increases the cost of the product.

The applicant's earlier patents listed above provide a novel method andapparatus for producing both large and small molded structurescontinuously. The apparatus includes unique combinations of componentsto produce a wide variety of different products. Achieving thiscapability requires a major capital investment. Also, personnel toutilize the broad parameters of the apparatus normally are highlytrained and experienced.

The present invention provides a novel molding method and apparatuswhich not only overcome the deficiencies of present technology but alsoprovide features and advantages not found in earlier expedients. Themultiaxis rotational molding method and apparatus of the inventionprovide a means for the production of a large number of uniform highquality products rapidly and efficiently.

The multiaxis rotational molding apparatus of the present invention issimple in design and can be produced relatively inexpensively.Commercially available materials and components can be utilized in themanufacture of the apparatus. Conventional metal fabricating procedurescan be employed by semi-skilled labor in the manufacture of theapparatus. The apparatus is durable in construction and has a longuseful life with a minimum of maintenance.

The apparatus of the invention can be operated by individuals withlimited mechanical skills and experience. A large number of high qualitymolded structures can be produced rapidly by such persons safely andefficiently with a minimum of supervision.

The molding method and apparatus of the invention can be modified tomold a wide variety of new structures. Variations both in productconfiguration and composition can be attained simply and convenientlywith the method and apparatus of the invention. Even with suchvariations, uniformity and quality of product dimensions and shapesstill are maintained without difficulty.

A novel method of the present invention for continuously formingintegrally molded structures includes the steps of rotating a pluralityof independently movable multisection mold assemblies about a pluralityof axes. A first freshly formed polymerizable mixture is supplied to afirst mold assembly. The first polymerizable mixture is flowed oversurfaces of a first enclosed mold cavity within the first mold assemblywhile selectively heating at least one of the mold sections of the firstmold assembly in a preselected heating profile. The flowing of the firstmixture over the first mold cavity surfaces, the heating of the moldsection and the formation of a first resin therefrom are monitored.

The first polymerizable mixture is supplied to a second mold assembly.The first polymerizable mixture is flowed over surfaces of a secondenclosed mold cavity within the second mold assembly while selectivelyheating at least one of the mold sections of the second mold assembly ina preselected heating profile. Simultaneously therewith, a freshlyformed second polymerizable mixture is supplied to the first moldassembly. The second polymerizable mixture is flowed over the firstresin within the first mold cavity while selectively heating at leastone of the mold sections of the first mold assembly in a preselectedheating profile. The flowing of the first and second polymerizablemixtures within the first and second mold cavities, the heating of themold sections and the formation of first and second resins therefrom aremonitored.

The first polymerizable mixture is supplied to a third mold assembly.The first polymerizable mixture is flowed over surfaces of a thirdenclosed mold cavity within the third mold assembly while selectivelyheating at least one of the mold sections of the third mold assembly ina preselected heating profile. Simultaneously therewith, the secondpolymerizable mixture is supplied to the second mold assembly. Thesecond polymerizable mixture is flowed over the first resin within thesecond mold assembly while selectively heating at least one of the moldsections of the second mold assembly in a preselected heating profile.The flowing of the first and second polymerizable mixtures within thesecond and third mold cavities, the heating of the mold sections and theformation of first and second resins therefrom are monitored.

The supplying of the first and second polymerizable mixtures succeedingmold assemblies and the flowing of the mixtures into the respective moldcavities while selectively heating the mold sections is continued untilall of the mold assemblies have received the mixtures. Also themonitoring of the flowing of the mixtures, the heating of the moldsections and the formation of resins therefrom are continued.

The rotation of the mold assemblies is continued throughout the steps ofthe continuous molding operation while monitoring individually each axisrotation of the mold assemblies. The monitored flowing of each mixture,the monitored heating of the mold sections and the monitored formationof each resin are coordinated with each monitored axis rotation in apreselected profile to form the integrally molded structures of thefirst and second resins.

The mold sections of each mold assembly are separated after theintegrally molded structure therein has achieved structural integritywithin the mold cavity. The structure is removed from the separated moldsections and the steps are repeated to form a multiplicity of theintegrally molded structures on a continuing basis. Advantageously, theintegrally molded structures are separated from the mold assembly bycooling the molded sections.

The method of the invention preferably includes the steps of flowing atleast one of the polymerizable mixtures into a mold cavity and rotatingthe cavity only a sufficient amount to coat the first mold sectionbefore heating the coated mold section to set the coating in place.Thereafter, the rotation of the mold cavity is continued to coat anadjacent second mold section followed by the heating of the secondcoated section to set the coating adhering thereto. Further rotationcoats each succeeding mold section and the heating thereof results inthe formation of an integrally molded product within the mold cavity.Subsequent cooling of the mold sections frees the molded structure fromthe mold assembly.

Advantageously, the mold assembly is transferred to an adjacent moldreceiving station prior to separating the mold sections and removing themolded structure. Thereafter, the mold assembly is returned to a moldingposition for repeating the method of the invention. A plurality of moldassemblies may be provided for each molding position so molding cancontinue while other mold assemblies are being opened and being preparedfor another molding cycle.

If desired, solid particles may be introduced into the mold cavity ofeach mold assembly and the particles distributed in a preselectedconfiguration before supplying the first polymerizable mixture to therespective mold assembly. Also, micro spheres may be introduced into atleast one of the polymerizable mixtures prior to molding.

Benefits and advantages of the novel multiaxis rotatable molding methodand apparatus of the present invention will be apparent from thefollowing description and the accompanying drawings in which:

FIG. 1 is a side view of one form of multiaxis rotational moldingapparatus of the invention;

FIG. 2 is a fragmentary top view of the molding apparatus shown in FIG.1;

FIG. 3 is an enlarged fragmentary side view of a molding portion of themolding apparatus shown in FIGS. 1 and 2;

FIGS. 4-11 are schematic illustrations of steps in the molding method ofthe present invention;

FIG. 12 is a side view of a further form of the multiaxis rotationalmolding apparatus of the present invention;

FIG. 13 is a side view taken from the left of the molding apparatusshown in FIG. 12;

FIG. 14 is a fragmentary side view of another form of multiaxisrotational molding apparatus of the invention; and

FIG. 15 is a fragmentary top view of a rotational drive portion of themolding apparatus shown in FIG. 14.

As shown in FIGS. 1-3 of the drawings, one form of multiaxis rotationalmolding apparatus 11 of the present invention includes a support portion12, a molding portion 13 and a control portion 14.

The support portion 12 of the multiaxis rotational molding apparatus 11of the invention includes a plurality of arm members 17,18,19,20disposed in a generally horizontal orientation. One end 21 of each armmember 17-20 extends from an upstanding frame section 22.Advantageously, the upstanding frame section 22 includes a centralupstanding section 23 from which the arm members extend radially asshown in the drawings.

The molding portion 13 of the rotational molding apparatus 11 includes aplurality of mold supporting assemblies 26. One mold supporting assemblyis rotatably mounted adjacent a free end 24 of each arm member 17-20.Each mold supporting assembly 26 includes an independently rotatablemold connector section 27. As shown in the drawings, the moldingapparatus preferably includes mold assembly receiving stations 28adjacent each arm member 17-20. The mold receiving stationsadvantageously also include mold transferring means such as hoist 29.

The molding portion 13 further includes a plurality of mold assemblies30,31,32,33. As shown in FIGS. 4-11 each mold assembly includes aplurality of separable mold sections 35,36,37,38 forming a substantiallyenclosed mold cavity 39. A heating element is associated with each moldsections 35-38. For example, mold section 35 includes heating element41; section 36, heating element 42; section 37, element 43 and section38, element 44.

The heating elements 41-44 advantageously include thermoelectricelements. Preferably, the thermoelectric elements function in anoperating temperature range providing heating and cooling as will bedescribed hereinafter.

Connecting means e.g. electromagnets 46 located in flange sections 47 ofthe mold sections (FIG. 3), selectively secure the assembled moldsections together. Also, connecting means 48 secure the assembled moldassembly to mold connector section 27.

The control portion 14 of the molding apparatus 11 of the presentinvention includes actuating means including drive means 50,51 for eachmold assembly. One drive means 50 rotates each mold supporting assembly26 and the mold assembly 30-33 affixed thereto. Another drive means 51rotates each mold supporting assembly 26 and the mold assembly affixedthereto along an axis generally perpendicular to the axis of rotationachieved with drive means 50. Other drive means may be provided foropening, closing, transferring mold assemblies, etc. as required.

The control portion 14 also includes programmable memory means 57,coordinating means 58, monitoring means 59 and circuitry therefor. Thedrive means 50,51 advantageously include gear motors, chains andsprockets connected thereto. Preferably, the gear motors are variablespeed motors. The actuating means may activate other components such aspumps, valves, drives, electromagnets, etc.

The coordinating means 58 advantageously includes a process controller60 that initiates changes in the flows of materials and speeds of drivesfor each mold assembly to bring variations therein back to therespective rates specified in the programs present in the memory 57.This coordination commonly is achieved through the transmission ofinformation such as digital pulses from the monitors and/or sensors atthe control components to the process controller 60.

The operating information is compared with the preselected programmingparameters stored in the memory 57. If differences are detected,instructions from the controller change the operation of the componentsto restore the various operations to the preselected processingspecifications.

In the use of the multiaxis rotational molding apparatus 11 of thepresent invention, the designs of the structures desired first areestablished. Then, each design is programmed into the memory 57.

To start the operation of the apparatus 11, buttons and/or switches of acontrol panel (not shown) are depressed to activate the memory 57 andthe other components of the control portion 14. The coordinating means58 energizes drive means 50,51.

Also, monitors 59 and pumps,, valves, etc. (not shown) are energized bythe coordinating means 58 in the preselected sequences of the programstored in the memory 57. This causes the raw materials in reservoirs(not shown) to advance along inlet conduits toward the respective moldassemblies 30-33. For example, to mold a structure including apolyurethane resin, one reservoir may contain a liquid reactive resinforming material, a second reservoir a particulate solid recyclablematerial and a third or more reservoirs—colors, catalysts, etc. asrequired.

To produce high quality molded structures of the invention, it isimportant that the raw material be uniform in volume and composition.This can be facilitated by providing a continuous flow of raw materialsand/or mixtures thereof onto the cavity surface of a mold assembly30-33. However, the volume of the mixture delivered will vary dependingupon the particular incremental area being covered at any instant. Also,the delivery to a particular mold assembly will be terminated completelywhen a molded structure is being removed from that assembly.

Advantageously, a separate bypass conduit (not shown) is utilized fromthe end of each inlet conduit at a point adjacent a particular moldassembly back to the respective reservoir. This construction providesfor the delivery of uniform raw materials and/or freshly formed mixturesthereof even though the distance is considerable between the reservoirsand the mold assemblies. The control portion 14 coordinates theoperation of the various system components so the required formulationflows onto the desired areas of a particular preselected mold cavity.

Rotation of each mold assembly 30-33 about an axis concentric with thatof mold connector section 27 and rotational movement of the moldassembly about a second axis perpendicular to its concentric axis arestarted and continue while the raw materials and/or freshly formedpolymerizable mixtures are transferred into each preselected cavity 39of a mold assembly. The multiple axis rotational movement and anyarcuate movement are continued to complete the flow of the mixture overall areas being covered within a particular mold cavity. All movementsare controlled within the parameters stored in the memory 57.

For particular structures, the movements about the respective axes maybe continuous and/or intermittent at changing rates. Also, it may bedesirable to provide arcuate rotation, that is, movement about an arcsuch as a rocking motion. Monitors 59 located within each mold assembly30-33 signal the process controller 60 when each polymerizable mixturehas been distributed over the preselected areas of the respective moldcavity so the controller can initiate the next step of the moldingmethod.

With the control components of the molding apparatus 11 activated, afirst dispenser 53 is aligned with the first mold assembly 30. Asschematically illustrated in FIGS. 4-11, a first freshly formedpolymerizable mixture is introduced into mold cavity 39 and flowsdownwardly by gravity onto the cavity surface of mold section 35disposed at the bottom of the cavity.

Thereafter, the mold assembly 30 is rotated to a position shown in FIG.5 wherein a coating 63 is forming on the cavity from the pool of liquid62 remaining in the mold bottom. Simultaneously with the rotation,heating element 41 of mold section 35 is energized to raise thetemperature of the cavity surface and set the coating to form a resinlayer thereof (FIGS. 5,6).

As the rotation of the mold assembly 30 continues a coating forms onmold section 36 emerging from the liquid pool therein (FIGS. 7,8).Heating element 42 is energized, heating mold section 36 setting thecoating and forming the resin layer in place. Further rotation of themold assembly forms resin layers over the surfaces of mold sections37,38 with the heating and setting of each coating as shown in FIGS.9,10.

When all of the mold sections have been coated, heated and set and thestructure being molded is complete, the heating elements 41-44 arede-energized causing the mold sections to cool and contract away fromthe integrally molded structure 64. This allows the structure to beseparated from the mold assembly so that the molding operation can berepeated. The flowing of the polymerizable mixture over the cavitysurfaces, the heating of the respective mold sections and the formationof a resin structure therefrom all are monitored during the moldingoperation.

To form multilayer structures, the steps described above may be repeatedand before the mold assembly is opened, a second freshly polymerizablemixture is introduced into the resin coated mold cavity and the stepsrepeated with the second mixture. The coatings formed on the cavitysurfaces are set in place by heating the mold sections sequentiallyforming a double walled structure. With the appropriate selection of theformulation of the mixtures, the resulting molded structure, forexample, may provide an integrally laminated two layer structure with adurable outer surface and a chemical resistant lining.

Continuous production of such structures can be achieved by aligning thefirst polymerizable mixture with an adjacent second mold assembly 31 andflowing the polymerizable mixture into the second mold cavity thereof.Simultaneously therewith, a second polymerizable mixture may be alignedwith the first mold assembly 30 and the mixture delivered into the moldcavity of the first mold assembly 30 flowing over the first resin formedin the cavity. The flowing of the first and second mixtures within thefirst and second mold cavities, the heating and setting of the coatingsand the formation of a first and second resin therefrom are monitored.

Thereafter, the first polymerizable mixture can be aligned with a thirdmold cavity of an adjacent third mold assembly 32 and the first mixtureflowed over the cavity surfaces as described above. Simultaneouslytherewith, the second mixture is aligned with the second mold cavity ofthe second mold assembly 31 and the second mixture flowed over the firstresin formed therein. The flowing of the first and second resins andformation of first and second resins therefrom are monitored.

The flowing of the first and second polymerizable mixtures into eachmold cavity of any additional mold assemblies is continued until all ofthe mold assemblies have received the mixtures according to thepreselected molding parameters. The monitoring of the mixture flow, theheating of the mold sections sequentially, the formation of resinstherefrom and mold assembly rotation are continued throughout themolding operation as well as the coordinating of this operatinginformation with the preselected program profile.

When a molded structure within a mold cavity is sufficiently cured thatit possesses structural integrity, rotation of the respective moldassembly is stopped and the mold assembly is transferred to an adjacentmold receiving station 28 with hoist means 29. The mold sections 35-38are separated by cooling them to free the structural unit.

The molded structure then may be set aside to complete the curing of theresin therein. During this period, the molded structure, free of themold's restraint, stresses the high density outer skin or layer. Thisstressing of the skin increases the strength and puncture resistancethereof and also the structural strength of the unit itself.

The mold sections 35-38 are prepared for another molding cycle. This mayinclude changing the position of one or more mold sections with respectto each other, the substitution of mold sections with differentconfigurations and the like. Also, cavity changing inserts may beemployed, if desired.

The mold sections then are assembled together and secured such as byenergizing electromagnets 46. The mold assembly now is ready forrepositioning on the adjacent arm member when the next mold assembly isremoved therefrom.

FIGS. 12 and 13 illustrate another form of rotational molding apparatus70 of the present invention. The apparatus provides for the molding oflarge structures on cantilever multi-axis molding apparatus withoutmajor reconstruction thereof.

The rotational molding apparatus 70 as shown in the drawings includes asupport portion 71 and a molding portion 72. The support portionincludes a vertical frame section 73 with a horizontally oriented armmember 74 extending therefrom. A U-shaped mold supporting assembly 76 isrotatably mounted on arm member 74 through a shaft 77.

A vertically disposed arcuate guide member 78 is mounted on framesection 73 in the path of one leg 79 of U-shaped mold supportingassembly 76. Drive means shown as motor 80 operatively connects the moldsupporting assembly 76 with guide member 78 and advances there along torotate the supporting assembly about shaft 77 as an axis. A moldassembly 81 is rotatably supported between the legs 79,82 of thesupporting assembly 76. The mold assembly is rotated about an axisperpendicular to shaft 77 by drive means 83 mounted on leg 82.

FIGS. 14 and 15 illustrate a further form of multiaxis rotationalmolding apparatus of the invention. Molding apparatus 84 includes asupport portion 85 and a molding portion 86. The support portion 85includes a plurality of drive wheel assemblies 87,88 selectively movablefrom a base surface 89 in a preselected drive profile. The drive wheelassemblies preferably are arranged in pairs and advantageously arepivotable about an axis perpendicular to the base surface.

The support portion also may include a frame section 90 shown as agenerally spherical configuration with a plurality of pairs of parallelendless tracks 91 arranged in a perpendicular orientation to other pairsof tracks 92. A mold assembly 93 is mounted within frame section 90along a central axis thereof. The tracks 91,92 preferably are recessesengageable with the drive wheel assemblies.

Structures may be formed with the molding apparatus 84 of the inventioncontinuously and automatically employing the control portion 14 ofmolding apparatus 11 described above. The control portion is programmedto selectively engage preselected drive wheel assemblies with theendless tracks 91,92 of spherical frame section 90. Rotation of thedrive wheels in a preselected rotational profile rotates a mold assembly93 supported thereby along a plurality of axes in the same way asdescribed above with molding apparatus 11 and 70. In addition, thecontrol portion can be programmed to transfer a mold assembly from onepair of drive wheel assemblies to an adjacent pair and onto the nextpair. In this way, the programmed memory not only can distribute apolymerizable mixture over a mold cavity, but also it can transfer amold assembly from one molding station to another.

The polymerizable mixtures employed to produce the structures of theinvention are selected to be capable of reaction to form the particularresin desired in the final structure.

Advantageously, the resin is a thermosetting resin such as apolyurethane or polyester. Should a polyurethane be desired, onecomponent may be an isocyanate and another may be a polyol. Morecommonly, different partially formed materials which upon mixinginteract to form the desired polyurethane may be employed. Examples ofsuch partially formed materials include so-called “A stage” resins and“B stage” resins.

Other resin forming systems may utilize a resin forming material and acatalyst. Additional components can be pre-mixed with one of the resinformers, e.g. fillers, reinforcements, colors and the like.

The particulate solid additive material may be any of a wide variety ofmaterials which impart special properties to the final structure such aswear resistance, lubricity, electrical, magnetic, temperatureconductivity or isolation, and the like. Some inexpensive particulatematerials generally are readily available at a particular job site.Natural mineral particulate material such as sand and gravel normallyare present or can be produced simply by crushing rock at the site.

Waste or recycled materials which can be shredded or ground intoparticles of suitable size can be utilized. Particularly useful areparticles formed by shredding or grinding discarded tires and similarproducts. Since the particles are encapsulated with the resin formingmaterial and not saturated therewith, many different waste materials maybe employed.

The above description and the accompanying drawings show that thepresent invention provides a novel multiaxis rotational molding methodand apparatus which not only overcome the deficiencies and shortcomingsof earlier expedients, but in addition provide novel features andadvantages not found previously. The method and apparatus of theinvention provide simple inexpensive means for producing uniform highquality products efficiently and at high rates of production.

The apparatus of the invention is efficient in its design and operationand is relatively inexpensive. Commercially available materials andcomponents can be utilized in the fabrication of the apparatus usingconventional metal working techniques and procedures.

Structures can be produced automatically with the apparatus of theinvention by operators with limited experience and aptitude after ashort period of instruction. The apparatus is durable in constructionand has a long useful life with a minimum of maintenance.

The method and apparatus of the invention can be utilized to mold a widevariety of different products. Variations in structure, configurationand composition of the products can be achieved simply and quickly withthe method and apparatus of the invention.

It will be apparent that various modifications can be made in themultiaxis rotational molding method and apparatus described in detailabove and shown in the drawings within the scope of the presentinvention. The size, configuration and arrangement of components can bechanged to meet specific requirements. For example, the mold assembliesmay be arranged differently with respect to one another. In addition,the number and sequence of processing steps may be different. Also, theapparatus may include other drive and actuating components andmechanisms.

These and other changes can be made in the method and apparatusdescribed provided the functioning and operation thereof are notadversely affected. Therefore, the scope of the present invention is tobe limited only by the following claims.

What is claimed is:
 1. A method of continuously forming integrallymolded structures in a multiaxis rotational molding operation includingthe steps of rotating a plurality of independently movable multisectionmold assemblies about a plurality of axes, supplying a first freshlyformed polymerizable mixture to a first mold assembly, flowing saidfirst polymerizable mixture over surfaces of a first enclosed moldcavity within said first mold assembly while selectively heating atleast one of said mold sections of said first mold assembly in apreselected heating profile, monitoring said flowing of said firstmixture over said first mold cavity surfaces, said heating of said moldsection and formation of a first resin therefrom, supplying said firstfreshly formed polymerizable mixture to a second mold assembly, flowingsaid first polymerizable mixture over surfaces of a second enclosed moldcavity within said second mold assembly while selectively heating atleast one of said mold sections of said second mold assembly in apreselected heating profile, simultaneously therewith supplying afreshly formed second polymerizable mixture to said first mold assembly,flowing said second polymerizable mixture over said first resin withinsaid first mold cavity while selectively heating at least one of saidmold sections of said first mold assembly in a preselected heatingprofile, monitoring said flowing of said first and second polymerizablemixtures within said first and second mold cavities, said heating ofsaid mold sections and formation of first and second resins therefrom,supplying said first polymerizable mixture to a third mold assembly,flowing said first polymerizable mixture over surfaces of a thirdenclosed mold cavity within said third mold assembly while selectivelyheating at least one of said mold sections of said third mold assemblyin a preselected heating profile, simultaneously therewith supplyingsaid second polymerizable mixture to said second mold assembly, flowingsaid second polymerizable mixture over said first resin within saidsecond mold cavity while selectively heating at least one of said moldsections of said second mold assembly in a preselected heating profile,monitoring said flowing of said first and second polymerizable mixtureswithin said second and third mold cavities, said heating of said moldsections of said second and third mold cavitys and formation of firstand second resins therefrom, continuing said supplying of said first andsecond polymerizable mixtures to succeeding mold assemblies and theflowing of the mixtures into the respective mold cavities whileselectively heating said mold sections until all of the mold assemblieshave received said mixtures, monitoring said flowing of said mixtures,said heating of said mold sections and formation of resins therefrom,continuing said rotation of said mold assemblies throughout said stepsof said continuous molding operation while monitoring individually eachaxis rotation of said mold assemblies, and coordinating said monitoredflowing of each mixture, said monitored mold section heating and saidmonitored formation of each resin with each monitored axis rotation in apreselected profile to form said integrally molded structures of saidfirst and second resins, separating said mold sections of each moldassembly after said integrally molded structure therein has achievedstructural integrity within said mold cavity, removing said integrallymolded structure from said separated mold sections and repeating saidsteps to form a multiplicity of said integrally molded structures ofsaid first and second resins on a continuing basis.
 2. A method ofcontinuously forming integrally molded structures according to themethod of claim 1 including the step of cooling said mold sections toseparate them from said integrally molded structure.
 3. A method ofcontinuously forming integrally molded structures according to themethod of claim 1 including the steps of flowing at least one of saidpolymerizable mixtures into a mold cavity, rotating said mold cavity tocoat a first portion thereof, heating the coated mold section to setsaid first portion, continuing the rotation of the mold cavity to coatan adjacent second portion thereof, heating the adjacent coated secondportion to set it and continuing the rotation of said mold cavity tocoat the remaining portions sequentially and heating each succeedingportion until the entire mold cavity is coated and set, and thereaftercooling all of the mold sections to separate them from a resultingintegrally molded structure.
 4. A method of continuously formingintegrally molded structures according to claim 1 including the steps oftransferring said mold assembly to an adjacent mold receiving stationprior to separating said mold sections and removing said structure fromsaid separated mold sections and thereafter returning said mold assemblyto a molding position for repeating the above steps.
 5. A method ofcontinuously forming integrally molded structures according to themethod of claim 1 including the step of providing a plurality of moldassemblies for each molding position so that molding can be continuedwhile other mold assemblies are being opened and prepared for repeatingthe above steps.
 6. A method of continuously forming integrally moldedstructures according to the method of claim 1 including the step ofintroducing solid particles into said first mold cavity and distributingsaid particles into a preselected configuration before supplying saidfirst polymerizable mixture to said first mold assembly.
 7. A method ofcontinuously forming integrally molded structures according to themethod of claim 1 including the step of introducing micro spheres intoat least one of said polymerizable mixtures.
 8. Multiaxis rotationalmolding apparatus including a support portion, a molding portion and acontrol portion; said support portion including an upstanding framesection, a plurality of spaced arm members each having one end extendingfrom said upstanding frame section; said molding portion including aplurality of mold supporting assemblies with one supporting assemblyrotatably mounted adjacent a free end of each of said arm members, eachof said mold supporting assemblies including an independently rotatablemold connector section, a plurality of mold assemblies each including aplurality of separable mold sections forming a substantially enclosedcavity, said mold sections including heating elements, connecting meansselectively securing mold sections of one mold assembly together and tosaid mold connector section; said control portion including meansdisposed on said frame section sequentially aligning material dispensingmeans and each mold cavity, actuating means rotating each mold connectorsection and said mold assembly selectively affixed thereto and actuatingmeans pivoting each mold supporting assembly and said mold assemblyaffixed thereto with respect to said arm member, programmable memorymeans storing preselected operating parameters, monitoring means sensingoperating information from control components, circuitry transmittingsignals from said monitoring means to coordinating means comparing saidoperating information with said operating parameters stored in saidmemory means and activating said orienting means and said actuatingmeans to control rotation of said mold assembly in a preselectedrotational profile, energizing of said heating elements of said moldsections in a preselected heating profile and formation of moldedstructures with said molding apparatus continuously in a preselectedmultiaxis molding profile.
 9. Multiaxis rotational molding apparatusaccording to claim 8 wherein said heating elements includethermoelectric elements.
 10. Multiaxis rotational molding apparatusaccording to claim 9 wherein said thermoelectric elements function in anoperating temperature range providing heating and cooling.
 11. Multiaxisrotational molding apparatus according to claim 8 wherein said rotatablemold connector section includes opposed spaced support sections. 12.Multiaxis rotational molding apparatus according to claim 8 wherein anarcuate guide member is associated with said frame section. 13.Multiaxis rotational molding apparatus according to claim 12 wherein oneof said support sections includes drive means selectively engageablewith said arcuate guide member.
 14. Multiaxis rotational moldingapparatus according to claim 8 including material dispensing means andaligning means providing relative movement between said dispensing meansand said mold assemblies.
 15. Multiaxis rotational molding apparatusaccording to claim 8 wherein said control portion includes actuatingmeans separating and assembling said mold sections.
 16. Multiaxisrotational molding apparatus according to claim 8 including moldassembly receiving stations adjacent said free ends of said arm members.17. Multiaxis rotational molding apparatus according to claim 16including means for transferring a mold assembly between said moldsupporting assembly and an adjacent mold receiving station. 18.Multiaxis rotational molding apparatus according to claim 8 wherein saidsupport portion includes a plurality of drive wheel assemblies arrangedin a preselected configuration and selectively movable from a basesurface in a preselected drive profile.
 19. Multiaxis rotational moldingapparatus according to claim 18 wherein said drive wheel assemblies areactivated in coordination with adjacent drive wheel assemblies toprovide rotation and movement of said mold assemblies in a preselectedmolding profile to form integrally molded structures continuously andautomatically.
 20. Multiaxis rotational molding apparatus according toclaim 18 wherein said mold assemblies include peripheral pathsengageable with drive wheel assemblies extending outwardly from saidbase surface to rotate said mold assemblies sequentially in apreselected rotational profile coordinated with the introduction ofpolymerizable mixtures into said mold cavities and the heating of moldsections in a preselected heating profile to continuously andautomatically form integrally molded structures.